Staff Design Engineer

GrayMatter Robotics•Carson, CA

2d•$135,000 - $250,000•Onsite

About The Position

GrayMatter Robotics is a well-capitalized Physical AI company headquartered in Los Angeles, building Factory SuperIntelligence (FSI) through systems that learn, adapt, and develop genuine process intelligence across every part they touch. Our robots take on the tedious, hazardous, and ergonomically demanding work that has kept manufacturing dependent on a shrinking skilled workforce, delivering superhuman performance. Robotics has a demo problem. GMR doesn't. Our systems are in active production today, adapting autonomously to real geometries, real materials, and real process variation without reprogramming. We deliver our system through a Robots-as-a-Service (RaaS) model that converts capital expenditure into an operating subscription, making Physical AI accessible to the manufacturers who need it most. We hire people who want to solve hard physical problems at an industrial scale. We help manufacturers improve the quality of life for their workforce while increasing production capacity, and reducing scrap, repair, and rework costs. As a Senior Design Engineer, you will join our Design & Mechatronics team onsite in our Carson, CA office to explore, develop and test novel systems in house for implementation in the field.

Requirements

BS/MS in Mechanical Engineering or equivalent experience
Demonstrated experience with 3D solid modeling, analysis, and development of 2D manufacturing drawings
Thorough understanding of manufacturing processes; manual machining, CNC machining, welding, sheet metal fabrication, plastic 3D prototyping
Thorough understanding of materials for manufacturing
8+ years working proficiency with CAD programs, hands-on prototyping, fabrication or ability to design for 3D printing
Proven track record of strong communication skills and ability to collaborate effectively across multiple teams and customers
Willingness to work at early stage company with dynamic priorities
Ability to conduct RCCAs and trade studies
Ability to solve problems effectively in a collaborative environment

Nice To Haves

8+ years working proficiency with SolidWorks
Experience with industrial robots and 6 DOF robotic arms
Experience machining, rapid prototyping and fabrication processes/materials to meet functional design requirements
Experience with project management
Experience with product deployment
Familiar with industrial facilities and equipment

Responsibilities

Design hardware and mechanisms for robotic systems, including system architectures, developing and reviewing new concepts with a primary focus on performance and reliability.
Collaborate with cross-functional teams to drive product improvements focusing on DFM (Design for Manufacturing) for End-of-Arm Tooling (EOAT) while ensuring compliance with ISO/TR 20218-1 safety guidelines.
Conduct complex Finite Element Analysis (FEA) and thermal simulations to validate structural integrity, predict failure modes, and optimize geometry before fabrication.
Perform foundational structural analysis and simulation to validate design integrity.
Prototype hardware considering Design for Manufacturability (DFM), utilizing tools such as 3D printers and CNC machines where appropriate.
Own the selection process for distinct electrical, mechanical, and pneumatic hardware components.
Collaborate closely with Electrical and Software teams to ensure seamless integration of motors, sensors, and cabling within the mechanical assembly.
Troubleshoot and test existing hardware and automation systems to identify opportunities for robustness and significant improvements.
Lead formal root cause investigations (e.g., 8D, Fishbone, 5 Whys) for field failures or manufacturing defects to implement permanent corrective actions.
Lead mechanical risk assessments (RA) and ensure system designs adhere to core industrial safety standards, including ISO 10218-1/-2 and ANSI/A3 R15.06.
Effectively implement GD&T (Geometric Dimensioning and Tolerancing), Tolerance Analysis, Design for Manufacturing, Design for Assembly.
Collaborate cross-functionally with internal and external teams to define customer requirements, validate project feasibility, and coordinate material procurement for in-house testing prior to deployment.
Organize part number allocation and review Bills of Materials (BOMs) for completeness to actively support inventory management and system deployment as well as maintaining an accurate BOM in PDM.
Execute Value Analysis/Value Engineering (VAVE) efforts to reduce Bill of Materials (BOM) costs without compromising system performance or reliability.
Manage relationships with external machine shops and component suppliers to ensure part quality, lead time adherence, and cost-effectiveness.
Make strategic recommendations for design validation and testing protocols.
Oversee the full mechanical product lifecycle from initial conceptualization through mass production and end-of-life support.
Lead, mentor, and actively develop junior talent within the engineering team.